Knitting Machine Yarn Tension Monitoring via Real-Time Pulse Detection
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Solution Overview
Problem
Existing methods for monitoring knitting machines require significant effort and time to detect broken needles, as they involve evaluating cumulative measurements of yarn tension across multiple needle passages, and often necessitate additional sensors.
Innovation Solution
A method and device that utilize a yarn tension sensor and a tension controlling unit with an actuator to regulate and monitor yarn tension, allowing for immediate detection of broken needles by identifying changes in yarn tension as a pulse, eliminating the need for additional sensors and reducing evaluation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cumulative measurements of yarn tension across multiple needle passages are evaluated to detect broken needles, then detection reliability is improved, but monitoring time and complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-defining threshold values for yarn tension deviations before monitoring begins. The control unit is pre-programmed with acceptable tension ranges, allowing immediate comparison of measured values against these thresholds to detect broken needles instantly, eliminating the need for cumulative evaluation across multiple passages.
Solution Approach 2:
The patent extracts the essential detection function by isolating the critical parameter (yarn tension deviation) from the complex cumulative evaluation process. By focusing solely on real-time tension threshold comparisons and removing the need to aggregate multiple measurements, the system achieves fast detection without sacrificing reliability.
2Measurement precision
If additional yarn tension sensors are installed between needles and yarn feeder to improve detection accuracy, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies multi-functionality by designing the yarn tension sensor system to serve dual purposes: the existing sensor in the yarn feeding device simultaneously performs both yarn tension regulation and broken needle detection functions. This eliminates the need for separate additional sensors, maintaining measurement precision while avoiding increased device complexity.
Solution Approach 2:
The patent merges the regulation and monitoring functions into a single integrated system. The control unit combines both the tension regulation control and the broken needle detection logic, allowing one sensor to fulfill multiple roles and reducing the overall sensor count while maintaining detection precision.
3Stability of the object's composition
If yarn tension is regulated by adjusting actuator means based on measured tension, then yarn tension stability is improved, but response time for broken needle detection may be delayed
Solution Approach 1:
The patent segments the control functions by separating the regulation loop from the detection logic. The control unit independently processes tension stabilization commands and broken needle detection evaluations, allowing simultaneous optimization of both yarn tension stability and detection speed without one function delaying the other.
Solution Approach 2:
The patent implements feedback by continuously monitoring yarn tension and immediately comparing it against predefined thresholds. When a deviation indicating a broken needle is detected, the system instantly generates a stop signal, while separately maintaining tension stability through continuous regulation, ensuring both stability and rapid detection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and accurate identification of broken needles, reducing the time and effort required for monitoring, with the ability to distinguish individual needle issues and notify a stop condition promptly, thus improving knitting machine efficiency.
Implementation Method 1
The yarn tension of the delivered yarn is measured by a yarn tension sensor
Implementation Method 2
The yarn tension is adjusted by an actuator means which comprises a yarn contact means
Data Source
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AI summary
A method for monitoring a knitting machine comprises: delivering a yarn (6) to the knitting machine (5) by a yarn delivering device (1,21 ); measuring the yarn tension of the delivered yarn (6) by a yarn tension sensor (4,23); monitoring a yarn parameter by a monitoring means (10), wherein the monitored yarn parameter is the measured yarn tension or is derived from the measured yarn tension; and determining a stop signal for the knitting machine (5) by the monitoring means (10) when a stop condition is notified. The method especially comprises: regulating the yarn tension of the delivered yarn (6) by a tension controlling unit (9); wherein the yarn tension is adjusted by an actuator means (2) which comprises a yarn contact means (3,22); wherein the yarn tension is regulated to a reference value (Tref) of the yarn tension by adjusting the actuator means (2) depending on the measured yarn tension; and wherein the monitoring means (10) is associated to the controlling unit (9).